Self-drilling expansion fastener and method of forming same

ABSTRACT

A self-drilling expansion fastener is integrally formed of a sheet metal material for locking two or more sheet workpieces together, and includes an expansion structure and a drill structure. The expansion structure has a plurality of internal threads and force-distributing bars. The drill structure has a chip guard for covering a head of the expansion structure, and a drill forward projected from the chip guar for self-drilling a hole. When an externally threaded element is screwed into the expansion structure to mesh with the internal threads, the force-distributing bars are brought to expand outward and are finally compressed into a folded state to thereby tightly lock the sheet workpieces to one another. A method of forming the self-drilling expansion fastener is also disclosed.

RELATED APPLICATIONS

This application is a Divisional patent application of co-pendingapplication Ser. No. 14/083,641, filed on 19 Nov. 2013, now pending. Theentire disclosure of the prior application, Ser. No. 14/083,641 isconsidered a part of the disclosure of the accompanying Divisionalapplication and is hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to an expansion fastener integrally formedof a sheet metal material, and more particularly to an expansionfastener capable of self-drilling a hole.

BACKGROUND OF THE INVENTION

An expansion fastening device is usually used to fixedly connectmultiple sheet workpieces, such as building panels, to one another, andincludes a bolt and an expansion fastener. FIG. 1 shows a typicalconventional expansion fastener 10, which includes a barrel body 11having a plurality of longitudinally extended elongated slots 12 formedthereon to define a plurality of laterally spaced middle bars 13; a nut14 connected to a head of the barrel body 11; and a bottom cover 15connected to a bottom of the barrel body 11. As shown in FIG. 2, a bolt16 can be extended through the bottom cover 15 and the barrel body 11 ofthe expansion fastener 10 to mesh with the nut 14. When the barrel body11 is subjected to a pull, the middle bars 13 are brought to expandoutward and become deformed. The deformed middle bars 13 and the bolt 16together lock an attached object 17 to a supporting object 18.

The conventional expansion fastener 10 is disadvantageous in terms ofassembling and installation thereof. First, the out 14 and the bottomcover 15 are connected to the barrel body 11 by welding, which is timeand labor consuming to result in high manufacturing cost of theexpansion fastener 10. Second, two steps are required to install theconventional expansion fastener 10 on a sheet workpiece, such as a panelor a board. That is, a hole having size corresponding to the expansionfastener 10 must first be drilled on the supporting object 18; and then,the barrel body 11 is driven into the hole with a hammer, for example,so that the barrel body 11 is tightly fitted in the hole without therisk of rotating relative to the supporting object 18. The aboveinstallation is apparently troublesome and consumes a lot of time andlabor. It is therefore desirable to overcome these disadvantages.

SUMMARY OF THE INVENTION

A primary object of the present invention is to provide a self-drillingexpansion fastener, with which a user can lock two or more sheetworkpieces together with only one installation step to largely simplifythe working procedure and upgrade the working efficiency.

Another object of the present invention is to provide a method ofintegrally forming a self-drilling expansion fastener from a sheet metalmaterial through a series of punching and stamping procedures, so thatthe self-drilling expansion fastener can be easily manufactured withupgraded production efficiency.

To achieve the above and other objects, the self-drilling expansionfastener according to the present invention is integrally formed of asheet metal material for locking two or more sheet workpieces together,and includes an expansion structure and a drill structure located at ahead of the expansion structure. The expansion structure has a pluralityof internal threads and a plurality of force-distributing bars. Thedrill structure has a chip guard for covering the head of the expansionstructure, and a drill forward projected from the chip guard forself-drilling a hole on the sheet workpieces, so that the expansionstructure can be extended through the sheet workpieces and tightlyreceived in the drilled hole with the force-distributing bars fullylocated behind the sheet workpieces. When an externally threaded elementis gradually screwed deeper into the expansion structure to mesh withthe internal threads, the force-distributing bars are brought to expandoutward and are finally compressed into a folded state to therebytightly lock the sheet workpieces to one another.

To achieve the above and other objects, the method according to thepresent invention for integrally forming a self-drilling expansionfastener includes the following steps:

-   (a) obtaining a sheet metal material having dimensions required for    forming the self-drilling expansion fastener, and defining an    expansion structure zone and a drill structure zone on the obtained    sheet metal material;-   (b) stamping the expansion structure zone at a specified location,    which is defined as a thread forming zone, to obtain threads having    required dimensions;-   (c) punching the expansion structure zone at a specified location,    which is defined as a barrel body forming zone, to obtain a    plurality of force-distributing bars;-   (d) punching the drill structure zone at a predetermined location to    obtain a required chip guard;-   (e) punching the drill structure zone at a predetermined location to    obtain a required drill; and-   (f) stamping the thread forming zone and the barrel body forming    zone to obtain required configurations for these two zones.

BRIEF DESCRIPTION OF THE DRAWINGS

The structure and the technical means adopted by the present inventionto achieve the above and other objects can be best understood byreferring to the following detailed description of the preferredembodiments and the accompanying drawings, wherein

FIG. 1 is an exploded perspective view of a conventional expansionfastener;

FIG. 2 is a sectional view showing the expansion fastener of FIG. 1 inuse;

FIG. 3 is a perspective view of a self-drilling expansion fasteneraccording to a preferred embodiment of the present invention;

FIG. 4 is a front plan view of the self-drilling expansion fastener ofFIG. 3;

FIG. 5 is a developed view of the self-drilling expansion fastener ofFIG. 3;

FIG. 6 is a cutaway view of the self-drilling expansion fastener of FIG.3;

FIGS. 7A to 7C sequentially show the steps of installing theself-drilling expansion fastener of the present invention; and

FIGS. 8A to 8I sequentially illustrate the steps included in a methodaccording to the present invention for forming the self-drillingexpansion fastener.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described with a preferred embodimentthereof and with reference to the accompanying drawings.

Please refer to FIGS. 3 to 6. A self-drilling expansion fastener 20according to a preferred embodiment of the present invention isintegrally formed of a sheet metal material, and includes an expansionstructure 21 and a drill structure 30 located at a head of the expansionstructure 21. The expansion structure 21 has a front portion formed intoan internally threaded body portion 22 and a rear portion formed into abarrel body portion 23. The internally threaded body portion 22 is acylindrical hollow body and defines a plurality of internal threads 24.

The barrel body portion 23 is a hexagonal hollow body and internallydefines a hex bore. The barrel body portion 23 includes a plurality oflaterally spaced force-distributing bars 25. Once the barrel bodyportion 23 is subjected to an axial pull, stress occurs at theforce-distributing bars 25. In other words, the force-distributing bars25 together form a weakening zone. In the preferred embodiment as shownin FIG. 5, there are six axially extended force-distributing bars 25being laterally equally spaced on the barrel body portion 23, such thata spacing slot 26 is formed between any two adjacent force-distributingbars 25. Further, the barrel body portion 23 includes at least oneretaining wing 27. In the illustrated preferred embodiment, as shown inFIG. 5, there are two retaining wings 27 formed on the barrel bodyportion 23 by stamping, so that these retaining wings 27 are outwardprotruded from a wall surface of the barrel body portion 23 and areslant at a fixed angle relative to a horizontal rear end of the barrelbody portion 23. And, the barrel body portion 23 includes at least onestopper 28 formed on the rear end thereof. Again, as can be seen in FIG.5, the illustrated preferred embodiment of the present invention has twodiametrically opposite stoppers 28, which are respectively upward bentfrom the rear end of the barrel body portion 23 to a sidewardlyprojected position.

The drill structure 30 includes a chip guard 31 and a drill 32. As canbe seen in FIG. 3, the chip guard 31 includes two side covers 33, whichare extended from the internally threaded body portion 22 and benttoward each other to together cover a front end of the internallythreaded body portion 22. It is noted two slits 35 are formed at twolateral sides of the joint of each side cover 33 and the internallythreaded body portion 22. The drill 32 consists of two drill bits 34,which are forward projected from top surfaces of the two side covers 33.

The expansion structure 21 further includes at least one coupling device40, which consists of a lug portion 41 and a notch portion 42correspondingly located opposite to the lug portion 41, such that thelug portion 41 and the notch portion 42 can be engaged with and lockedto each other.

FIGS. 7A to 7C illustrate the steps of installing the self-drillingexpansion fastener 20 on sheet workpieces. First, as shown in FIG. 7A,apply a rotating force on the barrel body portion 23 of theself-drilling expansion fastener 20, so that the drill 32 is brought todrill through multiple layers of sheet workpieces, such as an attachedobject 50 and a supporting object 51, for the stoppers 28 to tightlypress against the attached object 50. In addition to the two layers ofsheet workpieces shown in the embodiment, more than two layers may befastened by the fastener of the invention. At this point, as shown inFIG. 7B, the force-distributing bars 25 are located behind thesupporting object 51 and the retaining wings 27 are embedded in aperipheral wall of the drilled hole on the attached object 50, bringingthe self-drilling expansion fastener 20 to firmly associate with theattached object 50 and the supporting object 51. In practicalinstallation of the self-drilling expansion fastener 20, a matchinghexagonal tool 54 can be inserted into the barrel body portion 23 tofacilitate the rotation of the self-drilling expansion fastener 20,allowing the drill 32 to drill a hole on the attached object 50 and thesupporting object 51. The chip guard 31 functions to prevent any chipsof the workpieces 50, 51 from getting into the expansion structure 21.Thereafter, as shown in FIG. 7C, screw an externally threaded element 52into the barrel body portion 23 to fully mesh with the internal threads24 in the internally threaded body portion 22. When the externallythreaded element 52 is gradually screwed deeper into the internallythreaded body portion 22, the latter is gradually pulled backward tothereby compress the force-distributing bars 25, bringing the latter toexpand outward and finally be compressed into a fully folded state. Thefully folded force-distributing bars 25 are now tightly pressed againstan inner side of the supporting object 51, allowing the self-drillingexpansion fastener 20 to firmly lock the attached object 50 to thesupporting object 51. At this point, the externally threaded element 52has a front end extended beyond the drill 32 by a predetermined lengthto push open the side covers 33 of the chip guard 31, so that the drillbits 34 of the drill 32 are separated from one another.

In brief, the self-drilling expansion fastener 20 according to thepresent invention is integrally formed and has the ability ofself-drilling a hole, and can therefore be manufactured with fewercomponents to reduce the production and installation costs thereof.

The self-drilling expansion fastener 20 according to the presentinvention is formed of a sheet metal material through a series ofpunching and stamping procedures. FIGS. 8A to 8I sequentially illustratethe steps included in a method of the present invention for forming theself-drilling expansion fastener 20. First, as shown in FIG. 8A,unnecessary portions are removed from a sheet metal raw material toobtain the sheet metal material having dimensions for forming theself-drilling expansion fastener 20; a reference line “a” is defined todetermine an expansion structure zone 60 and a drill structure zone 70on the obtained sheet metal material; and the expansion structure zone60 is punched at a specified location to obtain at least one couplingdevice 61 and at a rear portion to obtain required stoppers 62. Then, asshown in FIG. 8B, the expansion structure zone 60 is stamped at aspecified location, which is defined as a thread forming zone 64, toobtain required threads 63. Then, as shown in FIG. 8C, the expansionstructure zone 60 is punched at a predetermined location, which isdefined as a barrel body forming zone 66, to obtain a plurality ofrequired force-distributing bars 65; and the drill structure zone 70 ispunched at predetermined locations to obtain required side covers 71 anddrill bits 72. Thereafter, as can be seen in FIG. 8D, the barrel bodyforming zone 66 is stamped at predetermined locations to obtain requiredretaining wings 67, and the thread forming zone 64 is punched atpredetermined locations to obtain slits 73 at joints of the side covers71 and the thread forming zone 64. Then, as shown in FIG. 8E, thestoppers 62, the side covers 71 and drill bits 72 are bent, no that theside covers 71 together form a required chip guard 74 and the drill bits72 together form a required drill 75.

As shown in FIGS. 8F to 8H, when the steps shown in FIGS. 8A to 8E arecompleted, the thread forming zone 64 and the barrel body forming zone66 are subjected to a series of stamping to respectively obtain arequired configuration. For example, the thread forming zone 64 isformed into a near-cylindrical hollow body and the barrel body formingzone 66 is formed into a hexagonal hollow body internally defining ahexagonal bore. Finally, as shown in FIG. 81, when the thread formingzone 64 and the barrel body forming zone 66 have been suitably shaped,the coupling devices 61 are closed to complete the self-drillingexpansion fastener 20 of the present invention.

By forming through a series of punching and stamping, the self-drillingexpansion fastener 20 can be easily and quickly completed with largelysimplified procedures, shortened working time and lowered manufacturingcost.

What is claimed is:
 1. A method of integrally forming a self-drillingexpansion fastener from a sheet metal material through a series ofpunching and stamping, comprising the following steps: obtaining a sheetmetal material having dimensions required for forming the self-drillingexpansion fastener, and defining an expansion structure zone and a drillstructure zone on the obtained sheet metal material; stamping theexpansion structure zone at a specified location, which is defined as athread forming zone, to obtain threads having required dimensions;punching the expansion structure zone at a specified location, which isdefined as a barrel body forming zone, to obtain a plurality offorce-distributing bars; punching the drill structure zone at apredetermined location to obtain a required chip guard; punching thedrill structure zone at a predetermined location to obtain a requireddrill; and stamping the thread forming zone and the barrel body formingzone to obtain required configurations for these two zones.
 2. Theself-drilling expansion fastener forming method as claimed in claim 1,wherein the chip guard includes two side covers and the drill includestwo drill bits.
 3. The self-drilling expansion fastener forming methodas claimed in claim 1, wherein the barrel body forming zone is stampedat a predetermined location to obtain at least one outward protrudedretaining wing, and the retaining wing being slant at a fixed anglerelative to a horizontal rear end of the barrel body forming zone. 4.The self-drilling expansion fastener forming method as claimed in claim1, wherein the thread forming zone is stamped into a near-cylindricalhollow body, and the barrel body forming zone is stamped into ahexagonal hollow body internally defining a hex bore.
 5. Theself-drilling expansion fastener forming method as claimed in claim 1,wherein the barrel body forming zone is punched at a predeterminedlocation to obtain at least one stopper.
 6. The self-drilling expansionfastener forming method as claimed in claim 1, wherein the expansionstructure zone is punched at a specified location to obtain at least onecoupling device for coupling two longitudinal sides of the expansionstructure zone to each other to complete the forming of theself-drilling expansion fastener.